Volvo Trucks North America, Inc.

Greensboro, NC USA
TSI
Date Group No. Supp. Page
This TSI Service Bulletin replaces TSI 213–002, “Cylinder
Liner, D12, D12A, D12B, D12C” (11.2001), publication no. 10.2003 213 002 1(14)
PV776–TSP160571.
Cylinder Liner
D12, D12A, D12B, D12C
Cylinder Liner

W2003244

Fig. 1: VOLVO D12C Engine

This information covers procedures for servicing the cylinder liners of VOLVO D12
engines.

Contents
• “Special Tools” page 2
• “Cylinder Liner, Removal (One)” page 4
• “Cylinder Liner and Piston, Wear Check” page 6
• “Cylinder Liner Height, Checking (One)” page 8
• “Cylinder Liner Seat, Overhaul” page 11

PV776-TSP194604 USA14031
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TSI 10.2003 213 002 2(14)

Tools
Special Tools
The following special tools are used to replace or repair components. The tools can be
ordered from Volvo. Please use the specified part number when ordering.

9989876 9992000 9992479

Dial Indicator Standard Handle for Drifts (25 x 200) Gauge Block

9992955 9996159 9996222

Puller Plate Adapter/Tap (for 9996161) Hydraulic Pump

9996394 9996395 9996599

Spacers Spacers Cylinder Liner Drift

9996606 9996645 9996854

Yoke Cylinder Liner Extractor Drift
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TSI 10.2003 213 002 3(14)

9996956 9996966 9998265

Flywheel Turning Tool Cylinder Liner Press Tool Ring Compressor

9998272 9998531 PT6400C

Milling Tool Piston Ring Compressor Cylinder Liner Puller

PT6410–4A 9996161
Puller Feet Hydraulic Cylinder
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TSI 10.2003 213 002 4(14)

Service Procedures
2131-01-01-01
Cylinder Liner, Removal (One)
(Cylinder head and oil pan removed)

You must read and understand the precautions and

guidelines in Service Information, group 21, "General
Safety Practices" before performing this procedure.
If you are not properly trained and certified in this
procedure, ask your supervisor for training before
you perform it.

Special tools: 9992955, 9996394, 9996395,

9996645, 9996956, 9996966, PT6400C,
PT6410–4A
1
Install clamping tool 9996966 on the cylinder liners that
are not to be removed.

9996966

C2001733

Fig. 2: Clamping tools installed (D12A/B/C shown)

2
Remove the inspection cover from the bottom of the
flywheel housing and install turning tool 9996956. Rotate
the flywheel until the connecting rod/piston to be
removed is in position.

9996956

3
Remove the piston cooling jet.

CAUTION
Do not bend tube. Doing so will permanently damage
the tube.

Note: If the jet is contaminated, refer to cleaning

procedure in Service Information, Group 22.
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TSI 10.2003 213 002 5(14)

4
Remove the connecting rod bearing cap and the bearing
shells.

5
Note: If the cylinder liner is excessively worn or carbon
has accumulated at the top of the liner, polish this area of
the liner so the piston may be easily removed.
Push up on the piston until the piston rings are above
the edge of the cylinder liner. Lift out the piston and the
connecting rod.

C2000448

Fig. 3: Forcing the piston up with a hammer handle

6
When reinstalling the cylinder liner, use a felt-tip pen
to mark on the block the correct position from which
the liner was removed.

7
Note: Must use puller feet PT6410–4A on liner puller
PT6400C to remove the liners. The use of other puller
feet can result in damage to the cylinder block.

Install cylinder liner puller PT6400C

(with puller feet PT6410–4A) into position on the cylinder
liner to be removed.

Note: Use either puller PT6400C or the Volvo liner puller

tool to remove the cylinder liners.

PT6400C, PT6410–4A

W2003962

Fig. 4: Pulling the cylinder liner (D12C)

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TSI 10.2003 213 002 6(14)

8
Install extractor 9996645 and puller plate 9992955 (with
spacers 9996394 and 9996395) into position on the
cylinder liner to be removed.

9996645, 9992955, 9996394, 9996395

C2002658

Fig. 5: Pulling the cylinder liner

9
Pull the cylinder liner out of the block.

10
Remove all sealing rings from the lower liner bore in
the cylinder block.

2131-06-04-01
Cylinder Liner and Piston, Wear Check
You must read and understand the precautions and
guidelines in Service Information, group 21, "General
Safety Practices" before performing this procedure.
If you are not properly trained and certified in this
procedure, ask your supervisor for training before
you perform it.

Thoroughly clean the cylinder liners and pistons before

inspecting and measuring. To thoroughly check for
cracks, remove the cylinder liner from the cylinder block.
Mark the position of the cylinder liner in the block with a
felt-tip pen before removing so it can be reinstalled in
the same position.
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TSI 10.2003 213 002 7(14)

Cylinder Liner
1
Check for cracks, paying special attention to the liner
collar. The magnesium powder method can be used
when checking.

Note: Pistons and cylinder liners are available from stock

only as matched pairs and cannot be mixed.

T2007071

Fig. 6: Checking the liner for wear

2
Bore wear measurements should be taken diagonally in
four height locations. The original bore size is 131 mm
(5.1547 in.). Wear should be no greater than 0.5 mm.
Total bore size should not exceed 131.5 mm (5.1771 in.).

3
If wear is greater than 0.45 – 0.50 mm (0.0177 –
0.0197 in.), use a complete liner kit (piston, liner, piston
rings, piston pin, and seals). Also consider engine oil
consumption to determine when to replace the cylinder
liner.

Pistons
4
Replace pistons that have deep scratches in the piston
skirt, a cracked or damaged piston ring land, worn ring
grooves, or a damaged snap-ring groove.
The two-piece piston must also have movement between
the skirt and crown.

W2003724

Fig. 7: Checking piston for wear

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TSI 10.2003 213 002 8(14)

2131-06-03-06
Cylinder Liner Height, Checking (One)
Cylinder Head Removed

Not Included:

• “Cylinder Liner Seat, Overhaul” page 11

You must read and understand the precautions and

guidelines in Service Information, group 21, "General
Safety Practices" before performing this procedure.
If you are not properly trained and certified in this
procedure, ask your supervisor for training before
you perform it.

Special tools: 9992000, 9992479, 9996159,

9996161, 9996222, 9996599, 9996606,
9996854, 9996966, 9989876
1
Remove the old seals from the cylinder block and
carefully clean the sealing surfaces. Use a brass wire
brush and cleaning fluid.

Note: Do not use scraping tools (or any tool that can
damage the sealing surface).

W2000727

2
If the cylinder liner seat has not been reconditioned,
install the cylinder liner without seals. Firmly attach the
liner, using two press tools 9996966.

9996966
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TSI 10.2003 213 002 9(14)

3
Install dial indicator 9989876 on gauge block 9992479
and zero the indicator against the cylinder block.

Note: The block and liner must be clean to ensure

accurate measurements.

9992479, 9989876

W2004329

Fig. 8: Zeroing the dial indicator against the cylinder

block.

4
If the cylinder liner is installed without a shim, an
even strand of jointing compound, approximately 0.8
mm thick, should be applied to the underside of the
cylinder liner collar.

Note: After applying jointing compound, the liner must be

installed within 20 minutes. If the cylinder head cannot
be installed and torqued within 20 minutes, the liner must
be secured under tension in the engine block with
two press tools 9996966.

9996966

T2008973

5
Install all sealing rings into the block and to the cylinder
liner, using the following tools:

9996161, 9996606, 9996222, 9996599

T2007154

Fig. 9: Pressing the liner into place in the block

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TSI 10.2003 213 002 10(14)

6
Measure the liner protrusion at four locations, 90
apart. Mark the liner against the block so that it can
be reinstalled in the correct position. Measure each
cylinder for each bore.

9992479, 9989876

W2004330

Fig. 10: Zeroing the dial indicator against the cylinder

block.

7
Lubricate the sealing rings with the lubricant provided
with the liner kit. Install them in the cylinder block.

Note: The violet sealing ring should sit in the lowest

groove.

T2019854

8
All liner protrusion should be within the following
specifications:

D12, D12A, D12B 0.15 – 0.20 mm (0.006 – 0.008 in.)

D12C 0.15 – 0.21 mm (0.006 – 0.008 in.)

Note: Once the liners have been installed, the liner height
variance between all cylinders is 0.06 mm

9
Lubricate the three lower seals that are to be placed in
the cylinder block with the lubricant provided with the
seals. The small O-ring seal that fits under the liner
collar does not require lubrication. Position the rings in
the grooves as outlined in the installation instructions
enclosed in the carton.
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TSI 10.2003 213 002 11(14)

2131-04-05-01
Cylinder Liner Seat, Overhaul
Not Included:

• “Cylinder Liner Height, Checking (One)” page 8

You must read and understand the precautions and
guidelines in Service Information, group 21, "General
Safety Practices" before performing this procedure.
If you are not properly trained and certified in this
procedure, ask your supervisor for training before
you perform it.

WARNING
Always wear appropriate eye protection to prevent
the risk of eye injury due to contact with engine
debris or fluids.

Note: A damaged cylinder liner seat can be repaired by

milling the liner shelf. Always add shims to compensate
for material removed by milling. Shims are available
in different thicknesses.
Special tools: 9992479, 9996966, 9998272,
9989876
1
Clean the liner seat and estimate the amount of wear.

Note: Do not use scraping tools.

2
Before milling the liner shelf, rough up the surface with
emery cloth to prevent dulling the cutter.

W2000727

Fig. 11: Roughing up liner seat

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TSI 10.2003 213 002 12(14)

3
Install a new liner with a shim, without liner packing, into
the bore. Measure the amount needed to be cut from the
liner ledge, and mark it for each bore.

Note: Available shims for D12C Engine:

0.020 mm (0.007874 in.), 0.030 mm (0.01181 in.),
0.050 mm (0.01968 in)

9992479, 9989876

W2003722

Fig. 12: Measuring the height of the cylinder liner

4
Remove the liner from each bore and mark it for that
cylinder bore.

5
Attach milling tool 9998272 to the cylinder block, making
sure that the feed sleeve does not press against the cutter.

9998272

T2007147

Fig. 13: Using milling tool 9998272

6
Note: Use a ratchet and socket to turn the cutter.
Do not use an air-powered tool.
When attaching the milling tool, tighten the feed bolt until
it presses lightly against the cutter. Install and set the
dial indicator at zero (0).

7
Turn the cutter with an even movement while turning
the feed sleeve at the same time.

8
While observing the dial indicator, continue cutting until
you have removed the estimated amount of material
measured to be cut from the bore.
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TSI 10.2003 213 002 13(14)

9
Stop the feed and rotate the miller several turns in order
to clean up any burs from the liner shelf

Note: When cutting the counter bore ledge, cut small

amounts in order to avoid cutting too much.

10
Remove the cutting tool. Install the liner with shim
and check the height.

11
If there is not enough material to cut out, remove the liner
and the shim. Install the cutter back into the bore and
remove the remainder of the material from the bore ledge.
Remove the cutter and again measure with the liner.

12
Install the cylinder liner without sealing rings. Firmly
attach the liner with two clamping tools 9996966.

9996966

T2007156

Fig. 14: Clamping tools 9996966 in place

13
Install a dial indicator 9989876 on gauge block 9992479
and zero the indicator against the cylinder block.

9989876, 9992479

W2003723

Fig. 15: Zeroing the dial indicator

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TSI 10.2003 213 002 14(14)

14
Place the indicator probe against the liner shelf and read
off the liner height above the face of the block.

W2003722

Fig. 16: Measuring the height of the cylinder liner

15
Repeat this measurement at four locations, 90
apart. Make a note of each dial indicator reading.
Sealing-surface height above the block face should be
within the following specifications:

D12, D12A, D12B 0.15 – 0.20 mm (0.006 – 0.008 in.)

D12C 0.15 – 0.21 mm (0.006 – 0.008 in.)

Liner height variance between all cylinders: 0.06 mm

Note: Measure at the highest point of the liner (convex

surface).

Note: Determine the number of shims required to allow

the liner to protrude above the block face within the
accepted specifications.

16
Remove the cylinder liner and install the recommended
shim for that cylinder.

Note: Use the fewest number of shims possible to

maintain specifications.

17
Reinstall liner with shims and clamp into place. Measure
height of liner above block face to confirm that it is
within specification. Mark the liner position so it can be
reinstalled in the correct position.

W2003722